Article of footwear incorporating a knitted component with a tongue

Abstract

Articles of footwear may have an upper that includes a knit element and a tongue. The knit element defines a portion of an exterior surface and an opposite interior surface of the upper, with the interior surface defining a void for receiving a foot. The tongue is formed of unitary knit construction with the knit element and extends through a throat area of the upper. Methods of manufacturing a knitted component for an article of footwear may include knitting a tongue. The tongue is held on needles of a knitting machine. A first portion of a knit element is formed with the knitting machine while the tongue is held on the needles. The tongue is then joined to the first portion of the knit element. Additionally, a second portion of the knit element is formed with the knitting machine.

The invention claimed is: 
     
       1. A method of manufacturing a knitted component for an article of footwear, the method comprising:
 knitting a tongue with a knitting machine; 
 holding the tongue on needles of the knitting machine; 
 knitting a first portion of a knit element with the knitting machine while the tongue is held on the needles; 
 joining the tongue to the first portion of the knit element; and 
 knitting a second portion of the knit element with the knitting machine. 
 
     
     
       2. The method recited in  claim 1 , further including a step of selecting the knitting machine to be a flat knitting machine. 
     
     
       3. The method recited in  claim 1 , further including a step of knitting an expansion section following the step of knitting the tongue, and wherein the step of knitting the first portion of the knit element includes unraveling the expansion section. 
     
     
       4. The method recited in  claim 1 , wherein the step of knitting the tongue includes forming a course of the tongue to include at least one of (a) a fusible yarn and (b) cross-tuck stitches. 
     
     
       5. The method recited in  claim 1 , wherein the step of joining the tongue includes forming a course with the knitting machine that joins the tongue to the knit element. 
     
     
       6. A method of manufacturing a knitted component for an article of footwear, the method comprising:
 knitting a tongue with a knitting machine; 
 knitting a first portion of a knit element with the knitting machine, the tongue being stationary with respect to a needle bed of the knitting machine during knitting of the first portion of the knit element, and the first portion of the knit element moving with respect to the tongue during knitting of the first portion of the knit element; 
 forming a course with the knitting machine that joins the tongue to the knit element; and 
 knitting a second portion of the knit element with the knitting machine, the tongue and the first portion of the knit element moving together during knitting of the second portion of the knit element. 
 
     
     
       7. The method recited in  claim 6 , further including a step of selecting the knitting machine to be a flat knitting machine. 
     
     
       8. The method recited in  claim 6 , further including a step of knitting an expansion section following the step of knitting the tongue, and wherein the step of knitting the first portion of the knit element includes unraveling the expansion section. 
     
     
       9. The method recited in  claim 6 , wherein the step of knitting the tongue includes forming a final course of the tongue to include at least one of (a) a fusible yarn and (b) cross-tuck stitches.